cGMP Reactor

What is a Pharmaceutical Reactor?

Pharmaceutical reactor is therefore a tool used for synthesizing products in a chemical actualization process manipulated under certain conditions. These reactions are very useful in the synthesis of API or active pharmaceutical ingredients which is the actual substance present in a drug. The reactor ensures the conditions necessary for a chemical change are maintained such as temperature, pressure and concentration of the reagents.

Types of Pharmaceutical Reactors:

• There are many types of reactors used in the pharmaceutical industry, each suited for specific reactions and production scales:
• Batch Reactors: These are general and widely used for mid-range to small productions. In batch reactor, at one go all reactants are charged to the reactor and the reservation is allowed to take place until it comes to an end. This type of catalysis is useful for processes in which the exact measure of time taken for the reaction and conditions under which it is carried out should be tightly controlled.
• Continuous Stirred Tank Reactors (CSTRs): can be applied for big production since the reactants are fed continuously and products are withdrawn simultaneously. This continuous operation is useful to sustain the quality and standard of the products in line with the concept of massive production.
• Plug Flow Reactors (PFRs): In PFRs, one of the reactants continuously flows through a tubular reactor in which the reaction takes place from end to end. This type is ideal for processes in which the continuous flow as well as equal reaction conditions are desirable.
• Fixed Bed Reactors: These reactors consist of a solid phase catalyst in which a flow through reaction takes place. Thus, fixed bed reactors are widely used in synthesizing drugs through catalytic reactions.

Features of Aquaon Engineers Pharmaceutical Reactors

• Material of Construction: Pharmaceutical reactors are mainly fabricated as per quality stainless steel SS 316L so that the reactor’s material does not get corroded by the processed chemicals. In certain circumstances, glass lined steel reactors may be used where the content is strongly corrosive or particular reaction is taking place
• Mixing: Many pharmaceutical reactions involve expectations of a certain mixing ability, which leads to the distribution of reactants and the rate of such a reaction. Stirrers are used to cause the reaction mixture to stir. Depending on the viscosity of the reaction mixture and desired mixing pattern the type of agitator to be used will be selected.
• Heating and Cooling: Temperature is very sensitive to the rate and selectivity of the reaction that occurs in the reaction mixture. Pharmaceutical reactors have jackets or coil for raising or lowering the temperature of the reaction mixture. It is managed through a thermostat or a process control system.
• Pressure Control:> The pressure inside the reactor can also have an impact on the occurrence of the reaction as well as its selectivity. Pharmaceutical reactors are designed to work at a certain pressure; it is always fitted with a pressure indicator and a pressure release device.
• Sampling Ports: Heating/head ports enable sampling of the reaction mixture during the reaction process so as to get samples of the mixture. This is very useful in tracking the rate of the particular reaction and may also be used to have a hold on the reaction conditions in case they are necessary to be altered.
• Cleaning and Sterilization: Pharmaceutical reactors being batch systems have to be cleaned and sterilized after every use to avoid cross contamination with the next product. This is usually achieved through a process of chemical cleaning and power washing; hot water washes and steam sterilization.
• Control Systems: Today’s pharmaceutical reactors are developed with advanced system of control whereby one can regulate the conditions of the reaction. Such systems are capable of recording the temperature, pressure, pH and other factors of the reaction and bring about changes where necessary all those required for the reaction to occur as planned.

Application of Pharmaceutical Reactors in Various Industries

• Pharmaceutical Industry: Pharmaceutical reactors are very essential in the pharmaceutical industries since they help in the synthesis and production of drugs and other medicinal products. These reactors are generally used for reactions which need to be carried out in a very specific and regulated manner to get products of very high purity and quality. It is employed in the deployment of processes such as crystallization, distillation, and mixing which go a long way in the preparation of APIs and intermediates. The need to control temperature, pressure, and pH levels is well suited in these reactors making them a key part of the pharmaceutical industry’s assurance of product safety and efficiency
• Chemical Industry: In the chemical industry especially in pharmaceuticals, reactors are used in many different methods of chemical synthesis and manufacturing. It is in the manufacturing of fine chemicals, special chemicals, and bulk chemicals production. It uses reactors in carrying out reactions such as polymerisation, hydrogenation and oxidation. It is characterised by tough construction enabling their use with corrosive and hazardous chemicals in efficient and sizable production. These reactors are easily daptable to large industries as well as experimental scale of work in laboratories.
• Food Industry: The food industry is one of the top industries where pharmaceutical reactors are used especially in production of food supplements, flavours, and colours. These are employed in operations in which the exact control of reaction conditions is needed to get particular characteristics of the product. For example, in the production of emulsifiers and preservatives reactors provide for proper blending and the reactions’ completion. Hygiene and safety layouts for reactors are ensured to avoid contamination of foods and to meet the high production quality of foods. Also, they assist in increasing production from pilot scale to large scale to discounts variations and inefficiencies.
• Beverages Industry: In the beverages industry, pharmaceutical reactors play a role in developing several constituents of beverages and extra ingredients. They are applied in fermentation, carbonation and mixing activities and other activities. For instance, in the process of making alcoholic drinks, reactors stabilize the fermentation process and the quality as well as the taste of the final product. Likewise in preparations of non-alcoholic beverages, reactors facilitate the process of combining requisite substances in order to get the requisite taste and stability of the product. Due to their capacity to meet and regulate the various reaction requirements freshers and other reaction contexts while maintaining sterility these reactors are essential for manufacture of secure and high-quality beverages.